Automating Complex Ingredient Handling for Large-Scale Snack Production Haldiram

Haldiram’s required a large-scale raw material handling system for several production lines, including recipe management for multiple ingredients. The client needed an automated system capable of handling a wide range of raw materials, including chickpeas, potato flakes, gram flour, potato starch, corn grit, rice grit, gram grit, semolina, soft flour, salt and sugar.

The main challenge was the complexity of the materials. Many ingredients were hygroscopic or sticky, making them difficult to store, dose and transport reliably. The client was also uncertain about using fabric indoor silos for these materials. In addition, the existing production process was labour-intensive and required better synchronization across operations.

ES Food Tech delivered a system with 22 storage silos, advanced PLC automation for ingredient traceability and accuracy, and ERP integration with the customer’s system.

The project enabled synchronized operations, minimized wastage, improved production efficiency and reduced labour costs through automation by approximately 80%.